Hockey blade with pin-reinforced core

ABSTRACT

A construct for a hockey blade that includes a foam core. The foam core includes a first core face, a second core face, and a bottom core edge and a top core edge. Multiple pins are injected into the foam core, and one or more layers of resin preimpregnated tape are wrapped around the foam before forming a hockey blade structure in a heated mold.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/148,613, filed Oct. 1, 2018, which is a divisional of U.S. patentapplication Ser. No. 15/280,603, filed Sep. 29, 2016, which isincorporated herein by reference in its entirety for any and allnon-limiting purposes.

FIELD

This disclosure relates generally to fabrication of molded structures.More particularly, aspects of this disclosure relate to hockey bladesmolded from foam that is reinforced with fiber pins and wrapped with oneor more layers of tape.

BACKGROUND

Hockey stick blades may be made of a core that is reinforced with one ormore layers of synthetic materials, such as fiberglass, carbon fiber orAramid. Aspects of this disclosure relate to improved methods forproduction of a reinforced hockey stick blade core.

SUMMARY

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. The Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used to limit the scope of the claimed subject matter.

Aspects of the disclosure herein may relate to fabrication of a formedhockey blade structure. In one example, the formed hockey bladestructure may include a fiber-pin-reinforced foam core. The fabricationof the formed hockey blade structure may include forming a foam core,injecting fiber pins into a first core face of the foam core, with thefiber pins extending between the first core face and a second core face.Additionally, the foam core may be wrapped with a layer of fiber tape,the wrapped foam core may be positioned within a mold, which is heatedand cooled to produce a formed hockey blade structure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is illustrated by way of example and not limitedin the accompanying figures in which like reference numerals indicatesimilar elements and in which:

FIG. 1 schematically depicts a perspective view of a foam core,according to one or more aspects described herein.

FIG. 2 schematically depicts an isometric view of the foam core of FIG.1, and including an array of regularly-spaced pins that have beeninjected into the foam core, according to one or more aspects describedherein.

FIG. 3 schematically depicts an isometric view of the foam core of FIG.1, and including an array of irregularly-spaced pins that have beeninjected into the foam core, according to one or more aspects describedherein.

FIG. 4 schematically depicts another isometric view of the foam core ofFIG. 1 with multiple pin injection areas for regularly spaced pins,according to one or more aspects described herein.

FIG. 5 schematically depicts another isometric view of the foam core ofFIG. 1 with multiple pin injection areas for irregularly spaced pins,according to one or more aspects described herein.

FIG. 6 schematically depicts an isometric view of the foam core of FIG.1 with a first area of regularly spaced pins, and a second area ofirregularly spaced pins, according to one or more aspects describedherein.

FIG. 7 schematically depicts a cross-sectional view of the foam core ofFIG. 1, according to one or more aspects described herein.

FIG. 8 schematically depicts another cross-sectional view of the foamcore of FIG. 1, and including multiple pins injected into the foam coreof FIG. 1, according to one or more aspects described herein.

FIG. 9 schematically depicts another cross-sectional view of the foamcore of FIG. 1, including multiple pins injected into the foam core ofFIG. 1 at an angle relative to a surface normal of a first core face,according to one or more aspects described herein.

FIG. 10 schematically depicts another cross-sectional view of the foamcore of FIG. 1 having multiple pins extending beyond a first core faceand a second core face, according to one or more aspects describedherein.

FIG. 11 schematically depicts another cross-sectional view of the foamcore of FIG. 1 having multiple pins injected into the foam core of FIG.1, and extending from an injection surface through to, and out beyond,an opposing surface of a second core face, according to one or moreaspects described herein.

FIG. 12 schematically depicts another cross-sectional view of the foamcore of FIG. 1 with multiple pins injected into a first core face, andextending into the foam core, without extending through to a second coreface, according to one or more aspects described herein.

FIG. 13 schematically depicts another cross-sectional view of the foamcore of FIG. 1 having pins injected at different angles, according toone or more aspects described herein.

FIG. 14 schematically depicts another cross-sectional view of the foamcore of FIG. 1 having a first set of pins injected into a first coreface, and a second set of pins, injected into a second core face,according to one or more aspects described herein.

FIG. 15 schematically depicts another cross-sectional view of the foamcore of FIG. 1 having multiple pins injected into the foam core atangles resulting in an overlapping pattern of pins, according to one ormore aspects described herein.

FIG. 16 schematically depicts a cross-sectional view of a wrapped foamcore, according to one or more aspects described herein.

FIG. 17 schematically depicts a cross-sectional view of the wrapped foamcore of FIG. 16, and including multiple pins injected into the wrappedfoam core, according to one or more aspects described herein.

FIG. 18 schematically depicts another cross-sectional view of thewrapped foam core of FIG. 16, including multiple pins injected into thewrapped foam core at an angle relative to a surface normal on a firstwrapped core face, according to one or more aspects described herein.

FIG. 19 schematically depicts another cross-sectional view of thewrapped foam core of FIG. 16 having multiple pins extending beyond afirst wrapped core face and a second wrapped core face, according to oneor more aspects described herein.

FIG. 20 schematically depicts a cross-sectional view of the wrapped foamcore of FIG. 16 having multiple pins injected into the wrapped foamcore, and extending from an injection surface through to, and out beyondan opposing surface of the second wrapped core face, according to one ormore aspects described herein.

FIG. 21 schematically depicts another cross-sectional view of thewrapped foam core of FIG. 16 with multiple pins injected into a firstwrapped core face, and extending into the wrapped foam core withoutextending through to a second wrapped core face, according to one ormore aspects described herein.

FIG. 22 schematically depicts a first set of pins injected at a firstangle relative to a first surface normal on the first wrapped core face,and a second set of pins injected at a second relative to a secondsurface normal on a first wrapped core face, according to one or moreaspects described herein.

FIG. 23 schematically depicts a cross-sectional view of the wrapped foamcore of FIG. 16 having a first set of pins injected into a first wrappedcore face, and a second set of pins injected into a second wrapped coreface, according to one or more aspects described herein.

FIG. 24 schematically depicts a cross-sectional view of the wrapped foamcore of FIG. 16 having multiple pins injected into the foam core atangles resulting in an overlapping pattern of pins, according to one ormore aspects described herein.

FIGS. 25A-25C schematically depict one implementation of a method forinjecting multiple pins into a foam core, according to one or moreaspects described herein.

FIGS. 26A-26C schematically depict another implementation of a methodfor injecting multiple pins into a foam core at a non-zero anglerelative to an injection surface, according to one or more aspectsdescribed herein.

FIGS. 27A and 27B schematically depict a pin injector that may beutilized to inject pins into a foam core without using a guide foamstructure, according to one or more aspects described herein.

FIG. 28 schematically depicts a plan view of a hockey stick blade,according to one or more aspects described herein.

FIG. 29 schematically depicts a first preform structure comprising oneor more layers of carbon fiber tape wrapped around a pin-injected foamcore, according to one or more aspects described herein.

FIG. 30 schematically depicts a partially-complete second preformstructure, according to one or more aspects described herein.

FIG. 31 is a flowchart diagram 3100 of a process for forming apin-reinforced molded structure, according to one or more aspectsdescribed herein.

FIG. 32 depicts an example of a form core hockey blade structure,according to one or more aspects described herein.

FIG. 33 depicts a close-up view of the foam core hockey blade structureof FIG. 32, according to one or more aspects described herein.

Further, it is to be understood that the drawings may represent thescale of different component of one single embodiment; however, thedisclosed embodiments are not limited to that particular scale.

DETAILED DESCRIPTION

In the following description of various example structures, reference ismade to the accompanying drawings, which form a part hereof, and inwhich are shown by way of illustration various embodiments in whichaspects of the disclosure may be practiced. Additionally, it is to beunderstood that other specific arrangements of parts and structures maybe utilized, and structural and functional modifications may be madewithout departing from the scope of the present disclosures. Also, whilethe terms “top” and “bottom” and the like may be used in thisspecification to describe various example features and elements, theseterms are used herein as a matter of convenience, e.g., based on theexample orientations shown in the figures and/or the orientations intypical use. Nothing in this specification should be construed asrequiring a specific three-dimensional or spatial orientation ofstructures in order to fall within the scope of this invention.

Aspects of this disclosure relate to systems and methods for productionof a pin-reinforced hockey stick blade by injecting one or more pinelements into a core structure of the hockey stick blade. Aspects ofthis disclosure may also be applied to pin-reinforcement of a hockeystick shaft, among others.

FIG. 1 schematically depicts a perspective view of a foam core 100. Inparticular, the foam core 100 is embodied with the geometry of a hockeystick blade. It is contemplated, however, that the foam core 100 may,additionally or alternatively, be shaped with the geometry of a hockeystick shaft, without departing from the scope of these disclosures. Incertain examples, foam core 100 may be a polymethacrylimide (PMI) foam.In one specific example, a Resin Infusion Manufacturing Aid (RIMA) lowdensity PMI foam may be utilized in the foam core 100. This type of foamis a high strength foam that can withstand the shear and impact forcesthat result when a hockey blade strikes a hockey puck. However, it iscontemplated that additional or alternative foam materials may beutilized to construct the foam core 100, without departing from thescope of these disclosures. In an alternative example, the foam core 100may be removed following one or more molding processes of the hockeystick blade. As such, the blade structure may be formed of compositestructures; carbon fiber walls that are reinforced by pins and moldedwith epoxy. In this alternative example, the foam may be removed by oneor more mechanical processes (one or more machine tools may be utilizedto remove the foam core 100, chemical processes (the foam may bedegraded/dissolved by the addition of/exposure to areactant/catalyst/solvent.

The foam core 100, as embodied in FIG. 1 with the geometry of a hockeystick blade, has a longitudinal length that is approximately parallel tothe depicted axis 102 (otherwise referred to as the x-direction 102,and/or the x-axis 102). Further, the hockey stick blade foam core 100has a height approximately parallel to the depicted axis 104 (otherwisereferred to as the y-direction 104, and/or the y-axis 104), and a depththat is approximately parallel to the depicted axis 106 (otherwisereferred to as the z-direction 106, and/or the z-axis 106). Further, thehockey stick blade foam core 100 includes a first core face 108, asecond core face 110, a top core edge 112, and a bottom core edge 114.

The hockey stick blade foam core 100, as depicted in FIG. 1, includes anoutline of a handle, or shaft portion shown in dashed lines toillustrate how the foam core 100, once ultimately formed into a blade,as described in this specification, is configured as part of a hockeystick that includes a blade and a handle, or shaft.

FIG. 2 schematically depicts an isometric view of the foam core 100 thatincludes an array 204 of regularly spaced pins that have been injectedinto the foam core 100. Pin 202 is labelled as one example pin withinthe array 204 of pins injected into the foam core 100. However, pin 202may or may not be substantially identical in shape, size, orientation,and/or injection depth, to one or more of the pins within the array 204.As such, the array 204 may include pins of differing geometries andconfigurations, or approximately uniform pins, without departing fromthe scope of these disclosures. Further, the array 204 may include anynumber of pins, without departing from the scope of these disclosures.The regular spacing, otherwise referred to as even spacing, between thepins of array 204 may measure any length. Additionally, a first spacingmay be equal to a first length along a first axis of the array 204 (e.g.along that axis approximately parallel to axis 102), and a secondspacing may be equal to a second length along a second axis of the array204 (e.g. along that axis approximately parallel to axis 104). Further,while the regularly spaced array 204 is depicted with perpendicular axesapproximately parallel to axes 102 and 104, it is contemplated that thearray 204 may have any orientation, without departing from the scope ofthese disclosures. Additionally, array 204 represents one example of aregularly-spaced array of pins, which may otherwise be referred to as apattern of pins. As such, it is contemplated that additional oralternative patterns of pin injection positions on the foam core 100 maybe utilized, without departing from the scope of these disclosures.

Advantageously, the array of pins 204 may be utilized to provideimproved strength and/or rigidity to a hockey stick blade that will,ultimately, be constructed from the foam core 100, according to thesystems and methods described in the proceeding disclosures. As such,the array of pins 204 may be generally utilized to reinforce the foamcore 100. The pins (e.g. pin 202), may be constructed from a fibermaterial (e.g. a synthetic fiber). In one example, the pins areconstructed from carbon fiber. In another example, additional oralternative fibers (e.g. glass fiber, Aramid fiber, or metallic pins(e.g. titanium, steel) among others) may be utilized to construct thepins. As such, the pins may be generally referred to as fiber pins. Thepins may, additionally or alternatively, be constructed from one or morepolymeric, metallic or alloy, and/or organic materials, withoutdeparting from the scope of these disclosures. In one implementation,the pins may be utilized to provide structural bridging elements betweenthe outer faces of the hockey blade, once molded. In certain examples,pins may be injected with different pin densities/pin injectiondensities into, in one example, the foam core 100. In oneimplementation, a pin injection density may be expressed as a number ofpins per unit area of the foam core 100 into which the pins areinjected. In another implementation, a pin injection density may beexpressed as a percentage in volume content of an overall volume of thefoam core structure into which the pins are injected. In yet anotherimplementation, a pin injection density may be expressed as an arealweight. It is contemplated that any pin injection density may beutilized, without departing from the scope of these disclosures. Incertain specific examples, a pin injection density expressed as a 0.5-5%volume content of the foam core may be utilized. In another example, apin injection density with a 5%-25% areal weight may be utilized.

In one example, the injected pins may be constructed from fiber (e.g.carbon fiber) that is coated in epoxy resin, or another adhesive type.In this example, the epoxy may be configured to melt, adhere tosurrounding structures, and re-solidify during one or more stages of amolding process, as described in the following disclosures. It iscontemplated that the pins may have a substantially cylindrical orprismal geometry. In one implementation, the pins may be shaped withopposing pointed and dull ends, or with two opposing pointed ends, amongothers. It is contemplated that the pins may have a cylindrical diameterof approximately 0.2-0.4 mm. However, it is further contemplated thatany pin dimensions, geometries and/or densities may be utilized, withoutdeparting from the scope of these disclosures. Further, it iscontemplated that the pins may have irregular geometries, withoutdeparting from the scope of these disclosures.

In another implementation, and as schematically depicted in FIG. 3, pinsmay be injected into the foam core 100 in a random, or pseudo-randommanner, as depicted by the grouping of pins 302. As such, there may beno regularity, or pattern to the pins within grouping 302.

In other examples, pins may be injected into specific areas of the foamcore 100 in order to selectively enhance the structural performance(e.g. strength and/or rigidity) of the hockey stick blade in areaslikely to be subject to comparatively larger forces during use of thehockey stick. FIG. 4 schematically depicts another isometric view of thefoam core 100 with multiple schematically-depicted pin injection areas402 and 404. Area 402 includes an array of patterned pins(regularly-spaced pins, of which pin 406 is one example pin) injectedinto the foam core 100 with a first injection density. Further, area 404includes an array of patterned pins, of which pin 408 is one examplepin, injected into the foam core 100 with a second injection density. Inthis exemplary embodiment, the spacing between the pins within area 404may be larger than the spacing between the pins within area 402. Assuch, area 402 may be referred to as having a higher injection densitythan area 404. It is noted that the positions of areas 402 on 404 aremerely one example. As such, any shape of pin injection areas may beutilized, and any number of pin injection areas on a single foam core100 may be utilized, without departing from the scope of thesedisclosures. In one specific implementation, one or more areas proximatethe bottom core edge 114, top core edge 112, and/or toe core edge 115may utilize a comparatively higher pin injection density in order toprovide increased resistance to wear and/or fracture of the hockey stickblade at or close to these areas. In another specific implementation,areas proximate one or more preferred impact areas on the hockey blade(preferred for making contact with a hockey puck during a shot motion),may utilize a comparatively higher pin injection density.

In another implementation, one or more areas of the foam core 100 may bedelimited for injection of pins with random, or irregular spacing, asschematically depicted in FIG. 5 by areas 502 and 504. As such, in oneexample, area 502 is depicted with a first group of irregularly-spacedpins injected with a first injection density (e.g. a first averageseparation between pin injection positions on a surface of the foam core100), and area 504 is depicted with a second group of irregularly-spacedpins injected with a second injection density (e.g. a second averageseparation between pin injection positions on the surface of the foamcore 100). In another implementation, multiple areas of the foam core100 may be delimited for injection with pins having a combination ofregular and irregular spacing. For example, FIG. 6 schematically depictsan isometric view of the foam core 100 with a first area 602 ofregularly-spaced/patterned pins, and a second area 604 ofirregularly/randomly-spaced pins.

FIG. 7 schematically depicts a cross-sectional view of the foam core 100along line 7-7 from FIG. 1. It is noted that the cross-sectional view ofFIG. 7 is merely one example of a cross-sectional geometry of the foamcore 100, and alternative geometries may be utilized, without departingfrom the scope of these disclosures. FIG. 8 schematically depictsanother cross-sectional view of the foam core 100, and includingmultiple pins, of which pin 802 is one example pin, injected into thefoam core 100. In one implementation, the cross-sectional view of FIG. 8is along the line 8-8 from FIG. 2, such that the pins depicted in FIG. 8are part of the array 204. As depicted in FIG. 8, the pins may extendfrom the first core face 108 to the second core face 110. In oneimplementation, the pins in FIG. 8 may be injected into the foam core100 at an angle relative to a surface normal 804 on the first core face108. In the example of FIG. 8, the pins may be injected as an angle ofapproximately 0° relative to the surface normal 804. In anotherimplementation, pins may be injected into the foam core 100 at anon-zero angle relative to the surface normal on the first core face108. FIG. 9 schematically depicts another implementation, includingmultiple pins, of which pin 902 is one example pin, injected into thefoam core 100 at an angle α 904 relative to a surface normal 906 on thefirst core face 108. It is contemplated that the angle α 904 may have arange of 5°-85°, 10°-80°, 15°-75°, 20°-70°, 25°-65°, 30°-60°, 35°-55°,40°-50°, or approximately 45°, among others.

In one example, when injected into the foam core 100, the pins mayextend out beyond the outer surfaces of the first core face 108 andsecond core face 110. In this regard, FIG. 10 schematically depictsanother cross-sectional view of the foam core 100 having multiple pins,of which pin 1002 is one example pin, extending beyond the first coreface 108 and the second core face 110. In one example, a portion of oneor more pins extending out from one or more of the first core face 108and the second core face 110 may be configured to embed into, one ormore layers of fiber tape that may be applied over the pin-injected foamcore 100. In another example, a portion of one or more pins extendingout from one or more of the first core face 108 and the second core face110 may be removed by one or more additional processes (e.g. cutting,grinding etc.).

FIG. 11 schematically depicts another cross-sectional view of the foamcore 100 having multiple pins, of which pin 1102 is one example pin,injected into the foam core 100, and extending from the injectionsurface 108 through to, and out beyond the opposing surface of thesecond core face 110. It is contemplated that, in anotherimplementation, the second core face 110 may be the injection surface inFIG. 11, such that when injected into the foam core 100, the pins (e.g.pin 1102) extend through to the first core face 108, and project outfrom the second core face 110.

FIG. 12 schematically depicts another cross-sectional view of the foamcore 100 with multiple pins, of which pin 1202 is one example pin,injected into the first core face 108, and extending into the foam core100, without extending through to the second core face 110. In oneexample, the pins (e.g. pin 1202) may extend to an approximate uniformdepth into the foam core 100. In another example, the pins (e.g. pin1202) may extend into the foam core 100 to differing depths.

In another implementation, pins may be injected into the foam core 100at different angles in different sections of the blade. In this regard,FIG. 13 schematically depicts another cross-sectional view of the foamcore 100 having pins injected at different angles in two differentsections. In particular, FIG. 13 schematically depicts a first set ofpins, of which pin 1302 is one example pin, injected at a first angle β1304 relative to a first surface normal 1306 on the first core face 108,and a second set of pins, of which pin 1308 is one example pin, injectedat a second angle γ 1310 relative to a second surface normal 1312 on thefirst core face 108. It is also contemplated, however, that the corecould be provided with additional sections having additional sets ofpins at different angles.

It is further contemplated that pins may be injected into multiplesurfaces of the foam core 100. For example, FIG. 14 schematicallydepicts another cross-sectional view of the foam core 100 having a firstset of pins, of which pin 1402 is one example pin, injected into thefirst core face 108, and a second set of pins, of which pin 1404 is oneexample pin, injected into the second core face 110. It is contemplatedthat pins may be injected into additional or alternative faces of thefoam core 100, without departing from the scope of these disclosures.For example, one or more pins may be injected into the top core edge 112and/or the bottom core edge 114, without departing from the scope ofthese disclosures.

In yet another example, pins may be injected into the foam core 100 inan overlapping configuration. FIG. 15 schematically depicts anothercross-sectional view of the foam core 100 having multiple pins, of whichpins 1502 and 1504 are exemplary pins, injected into the foam core 100at angles resulting in an overlapping pattern of pins, as depicted FIG.15. In particular, the pins may abut, or be positioned close to oneanother within the foam core 100 when in the overlapping patterndepicted in FIG. 15. The overlapping pins of FIG. 15, of which pins 1502and 1504 are examples, may be utilized to provide reinforcing structuresalong multiple directions. In one example, one or more of a group ofpins injected at different angles (e.g. the pins of FIG. 15) may resistshear forces within the hockey stick blade when molded. As such, the oneor more of the group of injected pins may be angled such that they willfail by being pulled out of the foam core 100, rather than failing byshearing. This pullout failure mode absorbs more energy than those pinsangled such that they will fail by shearing, and thereby offers morestrength to the hockey blade before the blade will fail (fracture etc.)

It is further contemplated that combinations of the pin injectionmethodologies discussed in relation to FIGS. 8-15 may be utilized,without departing from the scope of these disclosures. Additionally, itis noted that the pin injection methodologies discussed in relation toFIGS. 8-15 are a limited selection of possible pin injectionmethodologies, and additional or alternative pin injection patterns maybe utilized, without departing from the scope of these disclosures.

In one implementation, and as described in relation to FIGS. 7-15,multiple pins may be injected into an uncovered foam core 100. Inanother implementation, the foam core 100 may be wrapped with one ormore layers of carbon fiber tape prior to injection of the pins. Thecarbon tape may, in one example, be preimpregnated with epoxy resin, oranother adhesive material, which may be molded during one or moreprocessing stages described in the proceeding disclosures. In oneimplementation, the carbon fiber tape may be wrapped continuously aroundthe foam core 100. Accordingly, FIG. 16 schematically depicts across-sectional view of a wrapped foam core 1600 that includes one ormore layers of carbon fiber tape 1602 wrapped around the foam core 100.In one implementation, the one or more layers of carbon fiber tape 1602may be continuously wrapped around the first core face 108, the top coreedge 112, the second core face 110, and the bottom core edge 114,resulting in a first wrapped face 1604, a second wrapped face 1606, atop wrapped edge 1608, and a bottom wrapped edge 1610. In anotherimplementation, it is contemplated that the wrapped foam core 1600 may,additionally or alternatively, utilize one or more discontinuous lengthsof carbon fiber tape, without departing from the scope of thesedisclosures.

FIGS. 17-24 utilize similar pin injection methodologies to thosediscussed in relation to FIGS. 8-15, respectively, and include thewrapped foam core 1600 in place of the foam core 100. As such, FIG. 17schematically depicts a cross-sectional view of the wrapped foam core1600, and including multiple pins, of which pin 1702 is one example pin,injected into the wrapped foam core 1600. As depicted in FIG. 17, thepins may extend from the first wrapped core face 1604 to the second coreface 1606. In one implementation, the pins in FIG. 17 may be injectedinto the wrapped foam core 1600 at an angle relative to a surface normal1704 on the first wrapped core face 1604. In the example of FIG. 17, thepins may be injected at an angle of approximately 0° relative to thesurface normal 1704.

FIG. 18 schematically depicts another implementation, including multiplepins, of which pin 1802 is one example pin, injected into the wrappedfoam core 1600 at an angle α 1804 relative to a surface normal 1806 onthe first wrapped core face 1604.

FIG. 19 schematically depicts another cross-sectional view of thewrapped foam core 1600 having multiple pins, of which pin 1902 is oneexample pin, extending beyond the first wrapped core face 1604 and thesecond wrapped core face 1606.

FIG. 20 schematically depicts a cross-sectional view of the wrapped foamcore 1600 having multiple pins, of which pin 2002 is one example pin,injected into the wrapped foam core 1600, and extending from theinjection surface (first wrapped core face) 1604 through to, and outbeyond the opposing surface of the second wrapped core face 1606.

FIG. 21 schematically depicts another cross-sectional view of thewrapped foam core 1600 with multiple pins, of which pin 2102 is oneexample pin, injected into the first wrapped core face 1604, andextending into the wrapped foam core 1600, without extending through tothe second wrapped core face 1606.

FIG. 22 schematically depicts a first set of pins, of which pin 2202 isone example pin, injected at a first angle β 2204 relative to a firstsurface normal 2206 on the first wrapped core face 1604, and a secondset of pins, of which pin 2208 is one example pin, injected at a secondangle γ 2210 relative to a second surface normal 2212 on the firstwrapped core face 1604.

FIG. 23 schematically depicts a cross-sectional view of the wrapped foamcore 1600 having a first set of pins, of which pin 2302 is one examplepin, injected into the first wrapped core face 1604, and a second set ofpins, of which pin 2304 is one example pin, injected into the secondwrapped core face 1606.

FIG. 24 schematically depicts a cross-sectional view of the wrapped foamcore 1600 having multiple pins, of which pins 2402 and 2404 are examplepins, injected into the foam core 1600 at angles resulting in anoverlapping pattern of pins, as depicted FIG. 24.

FIGS. 25A, 25B, and 25C schematically depict one implementation of amethod for injecting multiple pins into a foam core. In particular, FIG.25A schematically depicts a foam core 2502. This foam core 2502 mayrepresent a cross-sectional view of a hockey blade foam core, or across-sectional view of a portion of a hockey stick shaft, among others.Further, the foam core 2502 may be similar to the unwrapped foam core100, or may be wrapped with one or more layers of carbon fiber tape,similar to the wrapped foam core 1600, without departing from the scopeof these disclosures. Pin injector 2504 may be utilized to urge one ormore pins into the foam core 2502 during one or more manufacturingprocesses. Accordingly, the pin injector 2504 may be configured to applya pressure to one or more pins, of which pin 2506 is one example pin,resulting in the one or more pins piercing the foam core face 2508, andtranslating into the foam core 2502. In one example, the pin injector2504 may comprise a manually-operated, or an automated device. Further,the pin injector 2504 may comprise a hydraulic, pneumatic, orscrew-driven actuator, among others. It is contemplated that variousactuator types (linear actuators, among others) may be utilized in thepin injector 2504, without departing from the scope of thesedisclosures. In another example, the pin injector 2504 may comprise anultrasonic hammer. It is also contemplated that additional oralternative apparatuses and/or methods may be utilized to urge one ormore pins (e.g. pin 2506) into the foam core 2502, and may be utilizedwithout departing from the scope of the disclosures described herein.

In one example, a set of one or more pins (e.g. pin 2506) may beretained within a guide foam structure 2510 prior to injection of theset of one or more pins into the foam core 2502. As such, the guide foamstructure 2510 may loosely retain the one or more pins 2506 at a desiredangle relative to the injection surface (foam core face 2508) on thefoam core 2502. In the depicted example of FIG. 25A, the pins 2506 maybe loosely retained within the guide foam structure 2510 at an angle ofapproximately 0° relative to a surface normal 2512 of the foam core face2508.

In one implementation, the guide foam structure 2510 may be looselypositioned proximate the injection surface (e.g. foam core face 2508) ofthe foam core 2502. In another implementation, the guide foam structure2510 may be coupled to the injection surface (e.g. foam core face 2508).The guide foam structure 2510 may be coupled using one or moreadhesives, and/or mechanical coupling elements. It is contemplated thatany coupling methodology may be utilized, without departing from thescope of these disclosures.

FIG. 25B schematically depicts the pin injector 2504 urging a set ofpins, of which pin 2506 is one example pin, into the foam core 2502.Accordingly, the pin injector 2504 may be configured to urge the pinsinto the foam core 2502 by translating along the direction indicated byarrow 2514. During injection of the pins 2506, the guide foam structure2510 may be deformed by the pin injector 2514. FIG. 25C schematicallydepicts the guide foam structure 2510 following the removal of the pininjector 2504, and shows the deformed area 2516 of the guide foamstructure 2510 following injection of the pins (e.g. pin 2506) into thefoam core 2502. In one example, the pin injector 2504 may inject allpins retained within the guide foam structure 2510 with a singleinjection pass/actuation. In another example, and as schematicallydescribed in FIGS. 25A-25C, pin injector 2504 may utilize multipleinjection passes to inject all of the pins retained within the guidefoam structure 2510. In one implementation, following injection of thepins from the guide foam structure 2510, a subset of one or more pins,in addition to a mass of deformed guide foam, may remain coupled to thefoam core face 2508. This remaining material may be removed by one ormore cutting, abrasive, or chemical processes, among others. In anotherexample, the guide foam structure 2510 may be configured to degrade anddisintegrate after a predetermined amount of time, and/or afterdeformation during one or more pin injection processes, and/or uponbeing exposed to air, water, and/or another solvent.

FIGS. 26A-26C schematically depict another implementation of a methodfor injecting multiple pins into a foam core at a non-zero anglerelative to an injection surface. Similar to the description of FIGS.25A-25C, a guide foam structure 2510 may be utilized to loosely-retain agroup of pins, of which pin 2602 is one example pin, at a non-zero angleδ 2604 relative to a surface normal 2606 of the injection surface (foamcore surface 2508). In one example, angle δ 2604 may have a range of5°-85°, 10°-80°, 15°-75°, 20°-70°, 25°-65°, 30°-60°, 35°-55°, 40°-50°,or approximately 45°, among others.

As schematically depicted in FIG. 26B, the pin injector 2504 may beconfigured to urge the pins 2602 into the foam core 2502 by translatingin a direction 2608 approximately parallel to a longitudinal length ofpins 2602. However, alternative pin injector geometries and translationpaths may be utilized, without departing from the scope of thesedisclosures. Similar to FIG. 25C, FIG. 26C schematically depicts thedeformed guide foam structure 2510 following injection of the one ormore pins into the foam core 2502, and removal of the pin injector 2504.

In another implementation, one or more pins may be injected into thefoam core 2502 without using a guide foam structure 2510. FIGS. 27A and27B schematically depict a pin injector 2702 that may be utilized toinject pins into a foam core 2502, without using a guide foam structure.In one example, one or more pins, of which pin 2704 is one example pin,may be loaded into the pin injector 2702, and the pin injector 2702 maybe positioned proximate an injection surface, such as foam core face2508. An injection angle (e.g. an angle c 2706 relative to a surfacenormal 2708) may be adjustable by the pin injector 2702. Further, thepin injector 2702 may utilize any actuation technology in order to urgethe pins 2704 into the foam core 2502. FIG. 27B schematically depictsthe pen injector 2702 following injection of a first set of pins,including pin 2704, into the foam core 2502. The pin injector 2702 maybe automatically or manually reloaded with a second set of pins,including exemplary pin 2710, as depicted.

Throughout this disclosure, reference is made to surface normals on oneor more surfaces of a hockey stick structure (e.g. one or more surfacesof a foam core 100, or a wrapped foam core 1600 of a hockey stickblade). FIG. 28 schematically depicts a plan view of a hockey stickblade 2800. As depicted in FIG. 28, it will be understood that a hockeystick blade may include complex curvature, such that a first surfacenormal 2802 may not be parallel to a second surface normal 2804.Accordingly, in one implementation, multiple pins may be injected at anangle relative to a single surface normal (e.g. the first surface normal2802), which may correspond to the point of injection of a single pinwithin a group of pins, or may not correspond to any of the points ofinjection of the pins within a group of pins, but may be a surfacenormal of an approximate center of an area into which a group of pins isto be injected. In one example, a group of pins injected into a foamcore (e.g. foam core 100 and/or foam core 1600), may be approximatelyparallel to one another. Further, it is noted that the complex curvatureof, among others, a hockey stick blade is three-dimensional. As such,three-dimensional coordinate systems (e.g. spherical coordinate system)may be utilized to define the angles discussed in the variousdisclosures described herein, and without departing from the scope ofthe aforementioned disclosures.

Following injection of one or more pins into a foam core, such as foamcore 100 or wrapped foam core 1600, one or more additional layers ofcarbon fiber tape may be wrapped around the foam core to produce apreform structure. In particular, the additional layers of carbon fibertape may be preimpregnated with epoxy resin.

The preform structure may be added to a mold, which urges it into adesired shape (e.g. a desired curve of a hockey stick blade). Thepreform, within the mold, may then be heated to a temperature at orabove the melting point of the resin within the preform (e.g. resinpreimpregnated into the carbon tape of the preform structure). Uponcooling, the resin solidifies, and maintains the shape of the mold uponextraction from the mold (e.g. maintains the desired hockey bladecurvature).

FIG. 29 schematically depicts a first preform structure 2900 comprisingone or more layers of carbon fiber tape wrapped around the pin-injectedfoam core 100 or 1600. Similar to the carbon fiber tape 1602 of thewrapped foam core 1600, the carbon fiber tape added after injection ofthe pins may be continuously wrapped. However, in anotherimplementation, the carbon fiber tape may be wrapped using multiplediscontinuous lengths of tape. It is contemplated that any pattern forwrapping the carbon fiber tape around a pin-injected foam core may beutilized. FIG. 29 schematically depicts a first wrapping pattern,whereby one or more layers of carbon fiber tape 2902 are wrapped withapproximately vertical wrappings. FIG. 30 schematically depicts apartially-complete second preform structure 3000. In this alternativeimplementation, one or more layers of carbon fiber tape may be addedonto the foam core 100 or foam core 1600 using diagonal wrappings. Assuch, wrappings 3002 may represent a first layer added to the foam core100 or foam core 1600, and wrappings 3004 may represent apartially-complete second layer added on top of the first layer 3002.

FIG. 31 is a flowchart diagram 3100 of a process for forming apin-reinforced molded structure. The processes described in relation toflowchart diagram 3100 may be utilized to produce a molded hockey stickblade structure, or hockey stick shaft structure, among others. In oneexample, a foam core may be formed by one or more manufacturingprocesses. It is contemplated that any suitable manufacturing processesmay be utilized to form a foam core, without departing from the scope ofthese disclosures. These manufacturing processes may include molding(injection molding or otherwise), cutting, stamping, or milling, amongmany others. The foam core may have a structure resembling that of ahockey stick blade without its desired, final curvature (e.g. the foamcore may be symmetrical, such that it does not yet have a curvaturedesigned for a right- or left-handed player). The foam core may besimilar to foam core 100, as previously described. In another example,the foam core may have a structure of a hockey stick shaft, amongothers. In one implementation, one or more manufacturing processes toform the foam core may be executed at block 3102 of flowchart 3100.

In one implementation, prior to injecting one or more pins, one or morelayers of tape may be added to the foam core. As previously described,the tape may be carbon fiber tape, and may be preimpregnated with resin.In another example, the described resin may additionally oralternatively include one or more thermoset or thermoplastic materials,include polyurethane (PU), Nylon, or polypropylene (PP), among others.In one implementation, the one or more layers of tape may be manually ormechanically added to the foam core to produce a wrapped foam core,similar to wrapped foam core 1600. These one or more processes executedto add one or more layers of tape to the foam core prior to injection ofone or more pins may be executed at block 3104 of flowchart 3100.Subsequently, one or more pins may be injected into the wrapped foamcore according to one or more of the processes described in relation toFIGS. 17-27. These one or more processes to inject one or more pins intothe wrapped foam core may be executed at block 3108 of flowchart 3100.

Alternatively, one or more pins may be injected into the unwrapped foamcore. As such, one or more pins may be injected into the foam core in amanner similar to one or more of those described in relation to FIGS.7-15 and 25-27. These one or more processes executed to inject one ormore pins into the foam core may be executed at block 3106 of flowchart3100.

One or more finishing processes may be used to prepare one or more ofthe outer surfaces of the foam core 100, or wrapped foam core 1600, foradditional layers of tape. These one or more finishing processes mayinclude one or more cutting and/or grinding/sanding operations toremove, in one example, portions of the injected pins protruding outfrom the surfaces of the foam core 100, or wrapped foam core 1600 (e.g.as described in relation to FIGS. 10, 11, 14, 19, 20, and 23).Additionally or alternatively, one or more finishing processes mayremove the deformed guide foam structure from the injection surface ofthe foam core 100, or wrapped foam core 1600. These one or moreprocesses may be executed at block 3109 of flowchart 3100.

Following injection of one or more pins into the foam core, one or moreadditional layers of tape may be added to produce a preform structure.The additional layers of tape may be preimpregnated with resin, and maybe wrapped in a manner similar to those described in relation to FIGS.29 and 30. Further, it is contemplated that the additional layers oftape may be manually or mechanically wrapped, without departing from thescope of these disclosures. As such, the one or more processes to wrapadditional layers of tape onto the pin-injected foam core may beexecuted at block 3110. It is contemplated, however, that the processesdescribed in relation to flowchart 3100 may not utilize block 3110 suchthat additional layers of tape may not be added to the foam core,without departing from the scope of these disclosures.

The preform structure produced by adding the additional layers ofpreimpregnated tape onto the foam core may be positioned within a moldstructure. It is contemplated that the mold structure may be configuredto urge the preform structure into any desired shape, without departingfrom the scope of these disclosures. In one specific example, the moldmay have a geometry of a desired hockey blade curvature. One or moreautomated or manual processes to add the preform structure to a mold maybe executed at block 3112 of flowchart 3100. Subsequently, the moldstructure may be heated equal to or above one or more meltingtemperatures of the resin within the preimpregnated tape and/or resinpre-applied to the pins prior to injection. Upon melting, the resin mayform new adhesive bonds between the internal elements of the preformstructure. In one example, if the injected pins are not pre-coated withresin, resin may selectively flow across the pins and adhesively bondthe pins to the foam core of the preform structure. In oneimplementation, the mold may be heated at block 3114 of flowchart 3100.In another implementation, it is contemplated that the resin describedin relation to flowchart 3100 may melt and form new adhesive bonds, butmay not flow when heated (e.g. the epoxy may not be configured to flowacross the pins structures). In another example, epoxy that ispre-coated onto pins may remain partially or fully solid when heated,and may bond to resin within the preimpregnated tape.

It is contemplated that any heating temperature and duration may beutilized, without departing from the scope of these disclosures.Further, any heating technology may be utilized, without departing fromthe scope of these disclosures. Following a heating period, the mold maybe passively or actively cooled. As such, upon re-solidification, theresin may retain the geometry of the mold cavity (i.e., retain thedesired geometry of the hockey blade, among others). Advantageously, theresin that may coat and bond the injected pins to the surrounding foamcore structure and fiber layers may add additional strength and rigidityto the hockey blade structure, once molded. In particular, the injectedpins may be utilized to connect the composite structures of the carbonfiber tape that forms the walls (e.g. the outer surfaces) of the hockeyblade structure, once molded. As such, once molded, the pins may serveas structural bridging elements between the outer contact surfaces ofthe hockey stick blade, thereby providing enhanced reinforcement to theblade structure.

One or more mechanical or automated processes configured to passively oractively cool the mold, and/or remove the molded structure, may beexecuted at block 3116 of flowchart 3100.

It is also contemplated that a resin transfer molding (RTM) techniquecould be employed in the formation of the hockey blade structure. Inthis example, the pins can be applied to a core and then wrapped with adry fiber material or the pins can be applied to a core already wrappedwith a dry fiber. The pins applied to a wrapped foam core may also helpto maintain the fibers onto the blade. Once the preform is constructed,a liquid thermoset resin can be used to saturate the dry fiber preformplaced in a mold to form the blade.

FIG. 32 depicts an example of a foam core hockey blade structure 3202,similar to the foam core 100 depicted in FIG. 2. In particular, FIG. 32depicts an array of fiber pins 3204 injected into the foam core 3202. Inone example, the fiber pins may be similar to pins 202. FIG. 32 alsodepicts a guide foam structure 3206. A plurality of fiber pins 3208 areheld within the guide foam structure 3206 prior to injection into thefoam core 3202. As such, the guide foam structure 3206 may be similar toguide foam structure 2510. FIG. 33 depicts a close-up view of the foamcore hockey blade structure 3202 of FIG. 32, including a close-up viewof a portion of the array of fiber pins 3204.

In one example, a formed hockey blade structure may be fabricated usinga method that utilizes a fiber-pin-reinforced foam core. The method mayinclude forming a foam core with a first core face, a second core face,a top core edge, and a bottom core edge. A group of fiber pins may beinjected into the first core face, with the group of fiber pinsextending between the first core face and the second core face. Further,a first fiber pin, from the group of fiber pins, may be injected at afirst angle relative to surface normal of the first core face at a firstpoint of injection of the first fiber pin. A second fiber pin, from thegroup of fiber pins, may be injected at a second angle relative to asurface normal of the first core face at a second point of injection ofthe second fiber pin. The foam core may be wrapped with a layer of fibertape that extends along the first core face, the top core edge, thesecond core face, and the bottom core edge of the foam core. As such,the wrapped core may have a first wrapped face, a second wrapped face, atop wrapped edge, and a bottom wrapped edge. The wrapped foam core maybe placed in a mold, and the mold. Then cooled before removing a formedhockey blade structure from the mold.

The method of fabricating the formed hockey blade structure may includespacing the fiber pins apart from one another at regular or irregularintervals on the first core face. Further, the method of fabricating theformed hockey blade structure may inject the group of fiber pins intothe first core face with a first spacing density, and inject a secondgroup of fiber pins into the first core face with a second spacingdensity.

In one example, one or more of the first angle and the second angle atwhich the first fiber pin and second fiber pin are injected into thefirst core face may be approximately equal to 0°, or may range between15° and 75°. In another example, the first angle and the second angle atwhich the first fiber pin and the second fiber pin are injected into thefirst core face may not be equal to one another. In yet another example,the first fiber pin and the second fiber pin may be approximatelyparallel to one another.

The group of fiber pins injected into the foam core may be constructedfrom carbon fiber or may be constructed from a resin-coated carbon fiberstructure. The coating resin may, in one example, be epoxy. However, inanother example, when pins are injected into the foam core using a guidefoam structure and an ultrasonic tool (e.g. ultrasonic hammer 2504), ahigh temperature resin may be utilized. In one specific example, abis-maleimide (BMI) resin may be utilized to coat the pins prior toinjection. Further, the group of fiber pins injected into the foam coremay be discrete, or disconnected from one another. In otherimplementations, pins injected into the foam core, as describedthroughout this disclosure, may be constructed from glass, aramid fiber,metal, ceramic, or combination thereof without departing from the scopeof these disclosures.

The fiber tape that is wrapped around the foam core may bepreimpregnated with resin, and may be continuously wrapped, or mayinclude multiple, discontinuous pieces.

In one example, the method of fabricating the fiber-pin-reinforced foamcore may inject the group of fiber pins through the foam core after ishas been wrapped with a first layer of fiber tape, such that the groupof fiber pins extend through the foam core and out through the secondwrapped face of the wrapped core. A second layer of fiber tape may bewrapped around the foam core after the plurality of fiber pins areinjected through the first wrapped face.

An ultrasonic hammer may be utilized to inject the group of fiber pinsinto the foam core. Additionally, a guide foam structure may bepositioned adjacent to the first core face prior to injecting the groupof fiber pins. The guide foam may be utilized to retain at least aportion of the group of fiber pins prior to injecting the fiber pinsinto the foam core.

In another example, a hockey blade structure may be formed by a methodthat includes forming a foam core, with a first core face, a second coreface, a top core edge, and a bottom core edge. A group of discrete fiberpins may be injected into the first core face, with the group ofdiscrete fiber pins extending between the first core face and the secondcore face. Further, the foam core may be wrapped with a layer of fibertape that extends along the first core face, the top core edge, thesecond core face, and the bottom core edge of the foam core to form awrapped foam core with a first wrapped face, a second wrapped face, atop wrapped edge, and a bottom wrapped edge. The method may additionallyinclude placing the wrapped foam core in a mold, heating the mold,cooling the mold, and removing a formed hockey blade structure from themold.

One or more fiber pins, from the group of discrete fiber pins, may beinjected at an angle relative to a surface normal of the first core facethe point of injection of the one or more fiber pins. This angle may beapproximately 0°, or may range between approximately 15 and 75°.Additionally, the fiber pins may be injected into a first area of thefoam core with a first spacing density, and a second group of discretefiber pins may be injected into a second area of the first core facewith a second spacing density. Further, the group of discrete fiber pinsmay be constructed from carbon fiber, aramid fiber, glass, metal, orceramic, or combinations thereof.

In another example, a method may include forming a foam core, injectinga group of pins structures through at least one surface of the foamcore, wrapping the foam core with a layer of fiber tape to form apreform, placing the preform in a mold, heating and cooling the mold,and removing a formed structure from the mold. Further, the plurality ofpin structures may be constructed from carbon fibers. Additionally, theformed structure may be a hockey blade, or a hockey stick shaft.

In yet another example, a hockey stick blade apparatus may include amolded preform structure that's has a foam core with a first core face,a second core face, a top core edge, and the bottom core edge. Themolded preform structure may also have a group of discrete fiber pinsthat extent between the first core face and the second core face withinthe foam core. A layer of fiber tape me extend along the first coreface, the top core edge, the second core face, and the bottom core edgeof the foam core.

Additionally, the layer of fiber tape utilized by the hockey stick bladeapparatus may be preimpregnated with resin prior to molding of themolded preform structure. Further, the group of discrete fiber pinsutilized within the hockey blade apparatus may be regularly spaced apartfrom one another.

In one implementation, the group of discrete fiber pins includes a firstsub-group of pins injected into the foam core with a first pin density,and a second sub-group of pins injected into the foam core with a secondpin density.

The present disclosure is disclosed above and in the accompanyingdrawings with reference to a variety of examples. The purpose served bythe disclosure, however, is to provide examples of the various featuresand concepts related to the disclosure, not to limit the scope of theinvention. One skilled in the relevant art will recognize that numerousvariations and modifications may be made to the examples described abovewithout departing from the scope of the present disclosure.

We claim:
 1. A hockey stick blade apparatus, comprising: a moldedpreform structure, further comprising: a foam core comprising a firstcore face, a second core face, a top core edge, and a bottom core edge;a first plurality of discrete pins injected substantially parallel toone another into a first area of the first core face with a firstspacing density and extending between the first core face and the secondcore face within the foam core; a second plurality of discrete pinsinjected substantially parallel to one another into a second area of thefirst core face with a second spacing density higher than the firstspacing density and extending between the first core face and the secondcore face within the foam core; and a layer of fiber tape extendingalong the first core face, the top core edge, the second core face, andthe bottom core edge of the foam core, wherein each of the firstplurality and the second plurality of discrete pins has two opposingpointed ends, wherein a portion of each of the first plurality and thesecond plurality of discrete pins extends out of the form core beyondthe first core face and the second core face, and wherein the portion isconfigured to embed into the layer of fiber tape.
 2. The hockey stickblade apparatus of claim 1, wherein the layer of fiber tape ispreimpregnated with resin prior to molding of the molded preformstructure.
 3. The hockey stick blade apparatus of claim 1, wherein thefirst plurality and the second plurality of discrete pins are regularlyspaced apart.
 4. The hockey stick blade apparatus of claim 1, whereinthe first plurality and second plurality of discrete pins extend throughthe layer of fiber tape.
 5. The hockey stick blade apparatus of claim 1,wherein the first plurality and second plurality of discrete pinscomprise fiber pins.
 6. The hockey stick blade apparatus of claim 1,wherein a selected pin, from the first plurality and the secondplurality of discrete pins, is injected at an angle relative to asurface normal of the first core face at a point of injection of a firstfiber pin.
 7. A hockey blade structure formed by a method comprising thesteps of: forming a foam core, the foam core comprising a first coreface, a second core face, a top core edge, and a bottom core edge;injecting a first plurality of discrete pins substantially parallel toone another at a first angle into a first area the first core face, thefirst plurality of discrete pins extending between the first core faceand the second core face; injecting a second plurality of discrete pinssubstantially parallel to one another at a second angle into a secondarea of the first core face, the second plurality of discrete pinsextending between the first core face and the second core face; wrappingthe foam core with a layer of fiber tape to form a wrapped core, thelayer of fiber tape extending along the first core face, the top coreedge, the second core face, and the bottom core edge of the foam core,wherein the wrapped core has a first wrapped face, a second wrappedface, a top wrapped edge, and a bottom wrapped edge; and molding thewrapped foam core in a mold, wherein the first plurality of discretepins has a first spacing density, and the second plurality of discretepins has a second spacing density higher than the first spacing density,wherein each of the first plurality and the second plurality of discretepins has two opposing pointed ends, wherein a portion of each of thefirst plurality and the second plurality of discrete pins extends out ofthe form core beyond the first core face and the second core face, andwherein the portion is configured to embed into the layer of fiber tape.8. The hockey blade structure of claim 7, wherein the first angle isrelative to a first surface normal of the first core face at a point ofinjection of a selected first pin, from the first plurality of discretepins, and the second angle is relative to a second surface normal of thefirst core face at a point of injection of a selected second pin, fromthe second plurality of discrete pins.
 9. The hockey blade structure ofclaim 8, wherein the first angle and the second angle are approximatelyzero degrees.
 10. The hockey blade structure of claim 8, wherein thefirst angle and the second angle are between approximately 15 and 75degrees.
 11. The hockey blade structure of claim 7, wherein the firstplurality and second plurality of discrete pins are regularly spacedapart from one another on the first core face.
 12. The hockey bladestructure of claim 7, wherein the first plurality and second pluralityof discrete pins comprise fiber pins.
 13. The hockey blade structure ofclaim 7, wherein the first plurality and the second plurality ofdiscrete pins are regularly spaced apart from one another on the firstcore face.